Kia Sorento: Cylinder Block Repair procedures

Kia Sorento (MQ4, 2021-2026) Service Manual / Engine Mechanical System / Cylinder Block / Cylinder Block Repair procedures

Disassembly

•	Use fender covers to avoid damaging painted surfaces.

•	Wait until the engine cools down to room temperature to avoid damaging the cylinder head before removing.

•	When handling the metal gasket, be careful not to fold or damage the surface.

•	To avoid damage, disconnect the wiring connectors carefully.

•	Mark all wirings and hoses to avoid misconnection.

•	Turn the crankshaft pulley so that the piston of No.1 cylinder is positioned at the top dead center (TDC).

1.	Remove the engine and transaxle assembly from a vehicle. (Refer to Engine And Transaxle Assembly - "Engine And Transaxle Assembly")

2.	Remove the automatic transaxle. (Refer to Automatic Transaxle System - "Automatic Transaxle")

3.	Remove the drive plate. (Refer to Cylinder Block - "Drive Plate")

4.	Remove the rear oil seal. (Refer to Cylinder Block - "Rear Oil Seal")

5.	Install the engine to engine stand for disassembly.

6.	Remove the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

7.	Remove the oil pan. (Refer to Lubrication System - "Oil Pan")

8.	Remove the timing chain cover. (Refer to Timing System - “Timing Chain Cover”)

9.	Remove the timing chain. (Refer to Timing System - “Timing Chain”)

10.	Remove the Integrated thermal management module (ITM). (Refer to Cooling System - "Integrated Thermal Management Module (ITM)")

11.	Remove the intake/exhaust CVVT and camshaft assembly. (Refer to Cylinder Head Assembly - "CVVT & Camshaft")

12.	Remove the intake manifold. (Refer to Intake And Exhaust System - "Intake Manifold")

13.	Remove the exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

14.	Remove the EGR cooler. (Refer to Intake And Exhaust System - "EGR cooler")

15.	Remove the cylinder head. (Refer to Cylinder Head Assembly - "Cylinder Head")

16.	Remove the oil pump. (Refer to Lubrication System - "Oil Pump")

17.	Remove the balance shaft assembly. (Refer to Lubrication System - "Balance Shaft Assembly")

18.	Remove the water pump. (Refer to Cooling System - "Water Pump")

19.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

20.	Refer to oil filter & oil cooler. (Refer to Lubrication System - "Oil Filter & Oil Cooler")

21.	Remove the lower crankcase. (Refer to Cylinder Block - "Crankshaft")

22.	Remove the piston and connecting rod assembly. (Refer to Cylinder Block - "Piston and Connecting Rod")

23.	Remove the crankshaft. (Refer to Cylinder Block - "Crankshaft")

24.	Remove the water jacket insert. (Refer to Cylinder Block - "Water Jacket Insert")

25.	Remove the knock sensor. (Refer to Engine Control/Fuel System - "Knock Sensor (KS)")

26.	Remove the crankshaft position sensor (CKPS). (Refer to Engine Control/Fuel System - "Crankshaft Position Sensor (CKPS)")

27.	Remove the piston cooling oil jet (A).

Inspection

1.	Remove the gasket debris on the top of cylinder block using a scraper.

2.	Clean the cylinder block thoroughly with a soft brush and solvent.

Measure the flatness of the top surface of cylinder block.

Measure the flatness of the surface in contact with the cylinder head gasket using the precise square ruler and feeler gauge.

Flatness of cylinder block gasket surface :

Less than 0.05 mm (0.0020 in.) for total area

Less than 0.02 mm (0.0008 in.) for a section of 100 mm (3.9370 in.) X 100 mm (3.9370 in.)

Engine Mechanical System — Cylinder Block / Repair procedures / Inspection illustration

4.	Visually inspect the inside of cylinder bore for scratches, etc., and replace the cylinder block if noticeable scratches are found.

Measure the cylinder bore inner diameter in the axial and axial orthogonal directions using a cylinder bore gauge.

Cylinder bore diameter :

88.50 - 88.53 mm (3.48425 - 3.48543 in.)

Engine Mechanical System — Cylinder Block / Repair procedures / Inspection illustration

Reassembly

•	Clean the each part before assembling.

•	Apply new engine oil on the sliding/rotating surface before assembling parts.

•	Always use the new gasket, O-ring and oil seal.

Install the piston cooling oil jet (A).

Tightening torque :

8.8 - 10.8 N·m (0.9 - 1.1 kgf·m , 6.5 - 8.0 lb·ft)

Engine Mechanical System — Cylinder Block / Repair procedures / Reassembly illustration

2.	Install the crankshaft. (Refer to Cylinder Block - "Crankshaft")

3.	Inspect the crankshaft end play. (Refer to Cylinder Block - "Crankshaft")

4.	Remove the lower crankcase and then inspect the oil clearance of crankshaft bearing. (Refer to Cylinder Block - "Crankshaft")

5.	Install the piston and connecting rod assembly. (Refer to Cylinder Block - "Piston and Connecting Rod")

6.	Inspect the oil clearance of connecting rod bearing cap. (Refer to Cylinder Block - "Piston and Connecting Rod")

7.	Inspect the connecting rod end play. (Refer to Cylinder Block - "Piston and Connecting Rod")

Assemble the other parts in the reverse order of disassembly.

When replacing the cylinder block, select and install the appropriate crankshaft main bearings and pistons according to the crankshaft journal bore mark and the cylinder bore size mark on the cylinder block

•	Crankshaft main bearing selection (Refer to Cylinder Block - "Crankshaft")

•	Piston selection (Refer to Cylinder Block - "Piston and Connecting Rod")

Crankshaft Repair procedures

Disassembly ...

Cylinder Head Assembly

...

Kia Sorento: Cylinder Block Repair procedures

See also:

Manuals list